Method of producing concrete structures.



G. W. GHAPPELOW.

METHOD OF PRODUCING CONCRETE STRUCTURES.

APPLICATION FILED FEB. 19, 1907.

Patented Oct. 19,1909.

3 SHEETS-SHEET 1.

G. W. CHAPPELOW. METHOI') OI PRODUCING CONCRETE STRUCTURES. APPLIOATION FILED PBBJIQ, 1907.

937,142, Patented Oct. 19,1909.'

3 SHEETS-SHEET 2.

C. W. CHAPPBLOW.

METHOD or monucme concnmn STRUCTURES. APPLICATION FILED FEB. 19, 1907.

Patented Oct. 19, 1909 3 BHEBTB-SHEBT 3.

- finished shells.

UNITED STATES PATENT OFFICE.

CHARLES WILLIAM CHAPPEIIOW, OF INDEPENDENCE, MISSOURI.

METHOD OF PRODUCING CONCRETE STRUCTUR-ES.

Specification of Letters Patent.

Patented Oct. 19, 1909.

Application filed February 19, 1907. Serial No. 358,273.-

To all whom it may concern:

Be it known that I, CHARLES \V CnAPrnLow, a citizen of the United States, and resident of Independence, in the county of Jackson and State of Missouri, have invented a new and Improved Method of Pro-' ducing Concrete Structures, of which the following is a specification.

My invention relates to a new and improved method of producing concrete structures, and more particularly to a method of producing monolithic concrete structures without the use of temporary molds or forms of any kind.

The primary object of my invention is to produce a permanent shell or form for use in concrete work which shell'or form becomes an integral part of the finished structure.

The further object of the invention is to provide means for forming concrete structures from such shells and to provide a method by which dead air spaces can be formed in connection with monolithic concrete work.

Vith the above, and other objectsin view, my invention consists in the method hereinafter described and illustrated in the accompanying drawings, in which- Figure 1 is a plan view illustratii'ig a method of forming my improved permanent shells, parts being broken away. Fig. 2 is a transverse sectional view of a wall in process of construction, according to m inve tion. Fig. 2 is asection through Fig. 1. 3 is a perspective view of a section of Fig. 4 is an enlarged frag? mentary-sectional view showing details of construction. Fig. 5 is a similar view illustrating a. modified construction. Fig, 6 is a similar view illustrating still another method of practicing my invention. Fig. 7 is a plan view showing various outlines of wall construction which may be produced by means of'my invention. Fig. 8 illustrates various forms of stays or anchors which I may employ. Fig. 8 illustrates various forms of division plates hereinafter described. Fig. 9

is atransverse sectional view illustrating a.

method of forming a floor structure by means of my invention. Fig. 10 is a fragmei'ita-ry sectional view of a modified construction of wall. Fig. 11 is a sectional View of a con crete floor constructed in accordance with my invention. Figs. 19., 13 and 14 are respectively an elevation, horizontal section, and

] vertical section of a beam and column, conlLLlAM a structed in accordance with my invention.

As heretofore constructed all monolithic concrete structures so far as I am aware, have been built in one of two ways. First, by erecting temporary forms, usually of wood, in order to hold the concrete in place 'until it is hardened. ..,econdly, by constructing a wall of hollow tiles or earthenware blocks. of various forms and afterward filling them in with concrete. In this construction, however, the tiles form a part of the supporting structure, and add materially to the strength of the finished wall.

In practicing my invention, I construct permanent forms or shells of cement mortar, or other plastic material, containing the active principle of cement, and after allowingthese to harden and setting them in the desired structural relation, I combine with them a mass of concrete. This concrete unites with the material of the shell, and forms a monolithic structure, the shell acting merely to hold the concrete in place until it has hardened, and not necessarily performing any function as a stress resisting material.

In carrying out my invention I proceed as follows; particular reference being had to Figs. 1 and 2. I provide a suitable platform, frame, or support A, having the confining walls F and on this support Ispread a uniform thin layer B of cement or similar plastic'materialh I then divide this layer into sections by means of transverse and longitudinally extending division plates F, preferably formed of sheet metal, and which are pushed down through the layer B while it is in a plastic condition, and allowed to remain. I next embed in each of the sections of the'layer B one end of suitably shaped anchors or stays E. After placing the stays and division plates-in position as above described, I deposit over the whole a layer C, of sand, sawdust, shavings or other loose and non-cohesive material. This layer of loose .material extends almost to the top of the in position, I pass a straight edge over the tops of the division plates F and thus smooth oti' the upper surface of the layer D, and render the same flush with the edges of the division plates.

If desired, and as shown in Fig. t, I may provide the division plates F with strips F of wood or suit-able material, extending along their upper edges and serving to form a groove or rahbet in the adjacent sections of cement shell.

While I have shown and described the supporting frame A as of sufiicient size to contain a large number of sections, it will be obvious that my invention can, if desired, be carried out with the use of a comparatively small frame, capable of containingbut two or three sections, or even a single section. division plates will be required.

After allowing the deposited material as shown in Figs. 1 and 2, to harden, I then separate the blocks or sections from each other. It will be readily seen, therefore, that by lifting out any section and simply jarring or shaking the same, the loose material (I, will slip out from between the two shells B and D, and these two shells being united by the stays E, the section will present the appearance shown in Fig. 3. These sections may then be placed, one upon another, edge to edge as shown in Fig. 2, and as the wall is built up,'concrete may be filled in between the shells, which when it hardens, will combine with the shells and form a solid monolithic structure enveloping the stays or anchors. It will now be obvious that. the strips F will have formed grooves in the edges of the sections or shells, and in these grooves, mortar may be inserted and pointed up for the purpose of giving'an ornamcntal appearance to theexterior of the .er'ably formed of steel or iron wire.

wall.

In Fig.8, I have shown various forms of stays or anchors that may be usefully employed. Those indicated by the letters H and I may be used in the relation shown in Fig. 4 for the purpose of stiffening and bracing the shells. All of these anchors are pref- Also as shown in this figure, I may employ a layer of-Water proof paper or similar material C, for the purpose of preventing the upper shells from sticking to the temporary core of loose material.

As shown in Fig. 5, the general method above described may be carried further and used to produce a wall composed of three shells I3. I3 and D. The stays used in this construction are designated by the letter G, and are formed with locking projections which embed themselves in each of the three shells. In constructing a Wall with shells of this type, the wider space between the shells B and D, is to be filled with concrete In this latter case, of course, no

'ing structures for insulation purposes.

in the usual manner. while the narrower space between the shells I3 and B, is to be left hollow and thus constitutes a dead air space in connection with the monolithic wa l. The principle illustrated in this figure may be extended still further, as may be necessary to produce walls of refrigerat- In some instances three, four or more thicknesses, with alternating dead air spaces may be desirable. The reference letters J and M in Fig. 8 illustrate forms of stays suitable for such construction.

In Fig. (l, I have shown my new method as applied to the production-of curved shells for use in constructing arches. chimneys and the like. The principle is identically the same, except that the support It employed is curved to the same radius as the structure to be produced. In this figure also, I have illustrated a still further modified form of anchor E It may sometimes happen. with any unusually heavy constructions, or for other reasons. that it is desirabh to embed separate anchors in each of the shells, and to connect them together after putting them in place. Fig. 13 illustrates such a construction. In Fig. 8, reference characters K and E 0 illustrate anchor suitable for this purpose, while N indicates an extension which may be employed between the members of the anchor K. It will thus be seen that suitable forms of anchors may be devised totrates a plate employed in such method a that shown in Figs. 1 and 2, while the reference character S illustrates a type of plate suitable for use in connection with the form of support shown in Fig. (i. U and T, illustrate division plates employed for producing angular shells as required for corners. Plates such as Vand X, are useful in forming pilasters such as shown at X, in Fig. 7, while the types of division plate indicated by W, Y and Z, are useful for forming the cement shell into any desired ornamental shape or configuration. As above explained, this is accomplished by moving the straight edge over the edges of these division plates after they have been set in position, and filled with cement.

In Fig. 7. I have illustrated various outlines of 'all construction to which my invention readily lends itself. As shown in the lower part of the figure, it may frequently be desirable to use a number of shells as indicated by B B and B etc., and to fill iii-between certain of them with concrete architects, but is wholly immaterial to my while the spaces between others are left empty so as to constitute dead air space. I have also illustrated in this figure at C, the use of building felt or waterproof paperwhich is sometimes desired and specified by invention. Fig. 10 illustrates more in detail the method of employing these layers of felt or the like, indicated at C ,'and which are cut to a size to fit the sections before being put in position.

It is frequently desirable, as illustrated at P in Fig. 7 'toprovide an opening in one of the shells for junction with a partition Wall, so thatthe concrete can flow from one wall to the other and form a monolithic structure. In order to provide openings of this kind, wherever desired, I lay on the platform orsupport A, in forming the shells, a suitable strip P, shown in Figs. 1 and 2*, around which the cement shell or layeris deposited. Openings for windows and the 4 (Fig. '9) on the platform A, and after em-' bedding therein suitable anchors E, and dividing the layer into sections by means of division plates F, I allow'them to harden.

It 'will be understood, of course, that the straight edge can be used in this connection, the same as above described. As shown in Fig. 11, the finished sections are then laid together on temporary wooden struts A with the anchors projecting upwardly, and a mass of concrete is then spread over the whole so as to envelop the anchors and firmly unite the sections of shell. When this concrete is hard, the struts A may, of

course, be removed.

It will thus be seen that I have devised a very practical and efiicient method of producing concrete structures, and it is thought the numerous advantages of my invention will be readily appreciated by those skilled in the art. i

VVhatIclaim is: y v 1. The hereindescribed method of 0011- crete construction which consists in the following steps; first, spreadinga' layer of plastic material upon a suitable support; fsecond,'d i-'1d1ng sa d layer into sections;

third, 'embeddingin eachsection, while in a soft" condition, one end ofsuitableanchors "orstaysffourth, allowing said sections to' harden, and when hard, laying or setting them in the desired structural relation; and

fifth, combining with said assembled sections a mass of wet concrete in such manner as to envelop said anchors or stays, and which when hard, unites with said sections to form a monolithic structure. a

2. The herein described method of producing permanent shells for concrete structures which consists first, in arranging on a suitable platform or support, any forms required by the finished structure: second,

spreadii'ig on said support a round said forms a layer of plastic material; third, dividing said layer into sections; fourth. embedding in each of said sections one end of suitable anchors or stays, fifth, spreading on said plastic material a layer of loose non-cohesive material; and sixth, spreading above said loose material and around said forms -asecond layer of plastic material in such position as to envelop the upper ends of said stays, and allowing said plastic material to harden.

bining with said as embled, sections a mass of concrete in such manner as to-envelcp said stays or anchors, whereby a i'nonolithicstructure results. i

t. The herein-described method of concrete constructionwhich consists in the following steps: first, in arranging on a suit able platform forms corresponding to the features required in the finished building; second, spreading on said platform around said forms a layer of plastic material; third, dividing said layer into sections; fourth. embedding in each such section one end of suitable anchors, having projecting free ends; fifth, removing said sections after they have hardened, and setting them in the structure being built in the same relation that they occupied when on the platform; and sixth, combining with such assembled sections a mass of concrete in such. manner as to'envelop the free ends of said anchors. 5. The herein-described method of .producing permanent shells for concretestructures which consists first, in spreading a layerof pl'astic'materialon asuitablesupport; second, di idingthe same. into secj'ti'ons by} means'ofdivision' plates Ofl any desiredshape; third,embedding in each of said sections whilesoft one end of suitable cohesive material, and plastic material in terial in such manner as to envelop the upducing permanent shells for concrete strucfrom between the shells.

stays: fourth. spreading on said layer of plastic material a layer of loose, non-cohesive material; fifth, spreading above said loose material a second layer of plastic inaper ends of said stays; sixth, passing a straight edge over said division plates and upper layer of plastic material, whereby the surface of the latter is made to conform with the contour of said plates; and seventh, separating said sections after the plastic material hashardened and dislodging the loose material from between the resulting shells.

6. The herein described method of protures which consists; first, in spreading a layer of plastic material on a suitable support; second, setting insaid layer a plurality of division plates of a width equal to the thickness of the finished wall; third, embedding in said layer while soft one end of suitable anchors or stays the other end of which erminates below the level of the upper edges of said division plates; fourth, spreading on said plastic material a layer of loose non cohesive material, extending nearly to the upper ends of said stays; fifth, spreading above said loose material a second layer of plastic material 1 1p to the level of the top edges of said division plates and enveloping the upper ends of said stays; and sixth, separating the sections formed the division plates after the plastic material has hardened and removing the loose material 7. The herein-described method of producing permanent shells for concrete structures which consists in spreading a layer of plastic material upon a suitable frame or support, embedding in such layer while soft, one end of suitable anchors,'spreadmg on such layer alternate layers of loose, nonsuch manner as to envelop said anchors, and, after the plastic material has hardened, removing the layers from the support and dislodgingthe loose material from between the resulting shells.

8. The herein-described method of producing concrete structures provided with 1 dead air spaces which consists in the following steps; first, spreading upon a suitable support a layer of plastic mater al; second, embedding therein one end ofsuitable stays or anchors; third, spreading on such layer alternate layers of loose and of plasticmaterial so as to envelop said anchors; fourth, after the plastic material has hardened removing the layers lrom the support and dislodging the loose material from between the same whereby multiple shells tied together by anchors are formed; fifth, setting said shells in the desired structural relation; and sixth, filling in the space between some of l the shells with concrete, and leaving the space between other of said shells empty, so as to form air spaces.

9. The herein described method of producing permanent shells for concrete structures which consists in the following steps; first, spreading in a suitable frame a layer of plastic material; second, embedding in said layer, one end of suitable stays or anchors; third, spreading a layer of loose noncohesive material on said first layer; fourth, spreading above said loose material a second layer of plastic material enveloping the upper ends of said stays; and fifth, withdrawing said layers from said frame after said plastic material has hardened, and removing the loose material from between the same.

10. The herein described method of producing concrete structures which consists in the following steps; first, spreading in a suitable frame alternate layers of plastic, and loose, non-cohesive material and so placing suitable anchors in said frame that they will become embedded in said plastic material during the spreading operation; second, Withdrawing the mass from the frame after the plastic material has hardened and removing the loose material from between the same; third, setting the shells thus formed in the desired structural relation; and fourth, filling in between some of the walls of said shells with wet concrete and allowing the same to harden, whereby a,

monolithic structure is produced.

11. The steps in a method of producing concrete structures which consist in forming a layer of plastic material of an area equivalent to that of a fixed surface of the completed structure, and while in plastic condition dividing the layer along predetermined lines corresponding to division lines in the finished structure, whereby the layer will have a surface configuration similar to that of the finished structure, and embedding within the layer one end of anchors or stays, then imposing on said layer a layer of loose non-cohesive material, then spreading another layer of plastic material on the nom cohesive material and enveloping the opposite end of the anchors or stays therein, said second layer of plastic material being divided on lines coinciding with the lines of division of the first layer, allowing the superposed layers to harden, and removing the interposed layer by removing the division-separatedsections of the hardened layers separately and eliminating the interposed layer of the several portions separately.

12. The method of producing concrete structures which consists in forming a layer of plastic material of an area equivalent to that of a fixed surface of the completed structure, and while in plastic condition dividing the layer along predetermined lines corresponding to division lines in the finished structure, whereby the layer will have a surface configuration similar to that of the finished structure, and embedding Within the layer one end of anchors or stays, then imposing on said layer a layer of loose non- -cohesive material, then spreading another of plastic material being divided on lines coinciding with the-lines of division of the first layer, allowing the superposed layers to harden, and removing the interposed layer by removing the division-separated sections of the hardened layers separately and eliminating the interposed layer of the several portions separately, then placing the sections in the structure to be formed in the relative positions occupied by them/ in the layer forming operation, and finally embedding the exposed portions of the'anchors or stays Within Wet concrete.

CHARLES WILLIAM CHAPPELOW. Witnesses WM. CRIoK, J. D. Bmoos. 

